Building block system

ABSTRACT

An interlocking concrete block for forming horizontal wall-channels for reinforcement of block walls of dry-stack, vertically-offset, double-wythe construction. The block has an outer block wall on one side and a head portion extending to the opposed side. The head portion has a connecting portion which interfits with a receptacle of a similar block. The block has a channel extending generally parallel to the outer block wall. In a block wall, two vertically-adjacent series of the blocks form a horizontal wall channel which can hold a reinforcing bar and in-filled concrete, for horizontal reinforcement of the wall.

FIELD OF THE INVENTION

This invention pertains to interlocking blocks for use in constructingbuildings and the like. More particularly, it pertains to interlockingblocks that form horizontal channels in a building wall. The channelscan be used for reinforcement of the wall.

BACKGROUND OF THE INVENTION

It is known in the art of building with concrete blocks to makedouble-wythe walls which comprise two vertically-offset series ofblocks, one series of which forms one wall face and the second series ofwhich interlocks with the first series and forms the opposed wall face.U.S. Pat. No. 6,508,041 Boot and U.S. Pat. No. 4,704,832 Vassiliadisshow examples of this type of wall system. It is used in the dry-stackconstruction of load-bearing and non-load-bearing walls.

Walls made using these systems can be reinforced by vertical members butthey do not provide for horizontal means of reinforcement, which limitstheir strength and stability.

SUMMARY OF THE INVENTION

The invention provides a form of block for vertically-offsetdouble-wythe wall construction, which blocks are arranged to formgenerally horizontal wall channels. The wall channels can accommodatereinforcing members and concrete in-fill for the purpose of reinforcingthe block walls. Buildings made with such horizontal reinforcement areconsiderably stronger than buildings made using prior art block systemslacking such reinforcement. In general terms, the block has an outerblock wall that defines a first side surface of the block and aninterlocking section for attachment to the interlocking section of acooperating interlocking block whose first side surface is opposite tothe first side surface of the block, and a channel that is open to thetop surface of the block.

The invention provides a block comprising an outer block wall on oneside of the block and a head portion extending towards the opposed sidesurface of the block. The head portion has a connecting portion whichinterfits with a receptacle of a similar cooperating block that ispositioned with its outer block wall opposite to that of the firstblock. The block has a channel extending generally parallel to the outerblock wall.

The invention further provides a building wall which includes suchblocks arranged so as to form a horizontal wall channel.

According to one preferred embodiment of the invention, there isprovided a block for use in interlocking with similar blocks in forminga substantially horizontal channel in a building wall. The blockcomprises a top surface, a bottom surface, an outer block wall defininga first side surface of the block and a head portion extending from theouter block wall towards an opposed, second side surface. The headportion defines at least one connecting portion. The block has at leastone receptacle substantially matching in shape the connecting portionfor receiving in interlocking relationship the connecting portion of acooperating interlocking block whose first side surface is opposite tothe first side surface of the block. The block has a channel open to theblock top surface extending generally parallel to the outer block walland having two opposed channel side walls and a channel bottom wall.

According to another preferred embodiment of the invention, there isprovided a block for use in interlocking with other similar blocks informing a substantially horizontal channel in a building wall, whichblock comprises a top surface, a bottom surface, an outer block walldefining a first side surface of the block, and a head portion extendingfrom the outer block wall toward an opposed, second side surface. Theblock has two connecting portions each on a respective side of the headportion. The block has two abutment portions each at a respective end ofthe outer block wall and each defining a respective abutment shoulder.There is a central groove in the head portion at a position thereonopposite to the outer block wall, the groove at opposite ends thereofdefining two inwardly facing shoulders each for engaging and retainingthe abutment portion of a respective one of two abutting blocks suchthat the abutment portions are retained end to end within the centralgroove. There is defined between the abutment portion and the connectingportion a receptacle substantially matching in shape the connectingportion for receiving in interlocking relationship the connectingportion of a cooperating interlocking block. The block defines a channelopen to the block top surface extending substantially parallel to theouter block wall and having two opposed channel side walls and a channelbottom wall.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate an exemplary embodiment of the invention:

FIG. 1 is a top perspective view of a block according to one embodimentof the invention;

FIG. 2 is a bottom perspective view of the block of FIG. 1;

FIG. 3 is a top plan view of the block of FIG. 1;

FIG. 4 is an end view of the block of FIG. 1;

FIG. 5 is a top plan view of three interlocking blocks;

FIG. 6 is a cross-sectional view on the line 6-6 of FIG. 5;

FIG. 7 is a perspective view of a portion of a building wall having twoseries of the blocks of FIG. 1 forming a horizontal wall channel; and

FIGS. 8 and 9 are a perspective and plan view respectively of a priorart block.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 to 4, which illustrate an exemplary embodiment ofthe invention, the block 10 has a top surface 12, a bottom surface 14,an outer wall 16 and a head portion 18. The block outer wall 16 definesone side surface 17 of the block. The head portion 18 extends to theopposed, second side surface 20. The head portion has a lobe-shapedconnecting portion 22 on each side thereof. The outer block wall 16 hasan abutment portion 36 at each end thereof, each defining an abutmentshoulder 38. Two concave receptacles 24, each between a respectiveconnecting portion 22 and abutment shoulder 38, have a shapecorresponding to that of a connecting portion 22 and are sized toreceive a connecting portion 22 of a second block in interlockingrelationship therewith. The head portion 18 has a central groove 40 at aposition opposite to the outer block wall 16. The groove 40 defines twoshoulders 42 which engage the abutment portions 36 of two abuttinginterlocking blocks.

A channel 26 in the block is open to the top surface 12 of the block andhas opposed side walls 28, 30 and a bottom wall 32. The channel 26extends generally parallel to the outer block wall 16. The channelbottom wall 32 is spaced from the bottom surface 14 by a distance thatis greater than the distance between the channel bottom wall and the topsurface 12, as explained below.

A hole 34 extends through the block from the top surface to the bottomsurface.

FIGS. 8 and 9 illustrate a prior art block 10P as disclosed in U.S. Pat.No. 6,508,041 Boot. The shape and size of the block 10 is such that itinterlocks with the prior art block 10P, which prior art block issimilar to the block 10 but it does not have any channel. In theillustration of the prior art block 10P in FIGS. 8 and 9, correspondingand like elements to those of the block 10 are indicated by the samereference numerals.

When used in the construction of a wall, the blocks 10 are intended tobe used in forming horizontal channels at selected heights, for exampleat a height of four feet in an eight-foot high wall. The blocks 10 arenot intended for construction of the entire wall, as horizontal wallchannels at every course are not necessary. It is intended that theremainder of the wall below and above such wall channel would beconstructed using the prior art blocks 10P.

In constructing a double-wythe wall using the blocks 10 and the priorart blocks 10P, a first course of prior art blocks 10P is made on asuitable footing along the perimeter of the structure. To do this, aseries of the prior art blocks 10P is placed at the external side of thewall to begin the external wythe and a series of half height blocks(identical to blocks 10P except one half the height) is placed at theinternal side of the wall to begin the internal wythe, interlocking withthe blocks of the first series. After this first course, all subsequentcourses consist of full height units (except where levelled at windowsills and at the wall top, where half height blocks are used). Theexternal series and the internal series of blocks are always offset fromeach other by one half of a block height as a result of placing halfheight blocks in the first course.

FIGS. 5-7 show the blocks 10 interfitting with like blocks. As best seenin FIG. 7, at a selected height in the construction of a wall, say fourfeet, the blocks 10 of the present invention are employed to form achannel for horizontal reinforcement of the wall. A first series 44 ofthe blocks 10 is laid to interlock with the uppermost course of theprior art blocks 10P. This series 44 of blocks 10 is laid with thechannels 26 facing upward. The connecting portions 22 of the uppermostcourse of the prior art blocks 10P are received in the respectivereceptacles 24 of the blocks 10, and the abutment portions 36 of theabutting blocks 10 are fitted in respective central grooves 40 of theprior art blocks 10P.

Before placing a reinforcing bar 58 in the horizontally-extending spaceformed by the channels 26 of the series 44 of blocks 10, the holes 34 inthe prior art blocks 10P and in the blocks 10 that will lie under thereinforcing bar are plugged sufficiently to retain the concrete that islater in-filled around the bar. The plugging can be done, for example,using crushed sheets of newspaper. Any holes 34 that will be used forvertical reinforcing bars 60 and in-filling of concrete are not plugged.

A reinforcing bar 58 is then placed in the horizontally-extending spaceformed by the channels 26, resting on the bottom wall 32 of the channels26. It will be apparent that, because the channel bottom wall 32 ishigher than the vertical midpoint of the block, the channel bottom wall32 of the blocks 10 is higher than the top surface 12 of the uppermostcourse of prior art blocks 10P, so the reinforcing bar 58 does not reston such top surface 12 but is supported only by the relatively narrowparts of the channel bottom wall that are on either side of the hole 34.This feature permits the concrete which is filled into the wall channel,as discussed below, to more completely surround the reinforcing bar andtherefore to better bond to it.

The horizontal reinforcing bars 58 are adjacent to the verticalreinforcing bars 60 that are positioned in holes 34 at selected spacing(for example 120 cm spacing) and can be affixed thereto by means oftwisted wire or the like.

After the reinforcing bar 58 is laid in position, a second series 48 ofthe blocks 10 is laid in interlocking arrangement with the first series44 to form the wall channel 52. The second series is placed with thechannels 26 facing downward. The connecting portions 22 of the blocks 10of the second series 48 are received in the respective receptacles 24 ofthe blocks 10 of the first series 44, and the abutment portions 36 ofabutting blocks 10 of the second series 48 are fitted in respectivecentral grooves 40 of the blocks 10 of the first series 44. The topsurface 12 of the blocks of the second series 48 faces downward andabuts the top surface 12 of the uppermost course of the prior art blocks10P. The channel bottom wall 32 of the blocks of the second series 48 isaccordingly spaced from and opposed to the channel bottom wall 32 of theblocks of the first series 44, and the channels 26 of the blocks of thefirst and second series collectively form a wall channel 52 extendinggenerally horizontally through the wall. It will be noted that thechannel 26 in each block 10 is sufficiently wide and is so positionedrelative to the width of the block that the channels 26 of the blocks ofone series overlap in longitudinal extension with those of the secondseries so that a continuous passageway through the wall, i.e. wallchannel 52, is formed by the block channels 26.

At this point in the construction of the wall, concrete is in-filledinto the wall channel 52 through the holes 34 in the blocks 10 of thesecond series 48, and into selected vertical channels (i.e. the channelscomprising aligned holes 34 in vertically positioned blocks 10 and 10P).Once the concrete has set, construction of the wall continues with aseries of prior art blocks 10P fitted to the second series 48 of theblocks 10, and so on to the desired wall height.

It will be apparent that the first side surface 17 of the blocks 10 ofthe first series 44 forms part of one vertical side surface 46 of thebuilding wall 54, and the first side surface 17 of the blocks 10 of thesecond series 48 forms part of the second, opposed vertical side surface50 of the wall. These parts are continuous with the respective sidesurfaces of the wall formed by the prior art blocks 10P that are belowand above the first and second series 44, 48 of the blocks 10.

Walls and buildings constructed using the blocks 10 can include endblocks for ending a wall and corner blocks for making corners in walls,as described in U.S. Pat. No. 6,508,041 Boot.

The block 10 of the invention is made of concrete, or alternatively ofclay or other suitable material. It is nominally 40 cm long, 20 cm highand 15 cm wide.

Apart from the use of concrete in the horizontal wall channels and inselected vertical channels, concrete is not used in the building of thewalls as the construction is dry-stack type, the blocks not beingmortared in place.

Although the invention has been described in terms of specificembodiments, it is not intended that the invention is limited to thoseembodiments. Various modifications within the scope of the inventionwill be apparent to those skilled in the art. The scope of the inventionis defined by the claims that follow.

1. A block (10) for use in interlocking with other similar blocks informing a substantially horizontal channel (52) in a building wall (54),the block comprising: a top surface (12); a bottom surface (14); anouter block wall (16) defining a first side surface (17) of the block;an interlocking section for attachment to the interlocking section of acooperating interlocking block whose first side surface is opposite tothe first side surface of the block; and a channel (26) open to theblock top surface (12) extending generally parallel to the outer blockwall and having two opposed channel side walls (28, 30) and a channelbottom wall (32).
 2. A block (10) for use in interlocking with othersimilar blocks in forming a substantially horizontal channel (52) in abuilding wall (54), the block comprising: a top surface (12); a bottomsurface (14); an outer block wall (16) defining a first side surface(17) of the block; a head portion (18) extending from the outer blockwall towards an opposed, second side surface (20); the head portiondefining at least one connecting portion (22); at least one receptacle(24) substantially matching in shape the connecting portion (22) forreceiving in interlocking relationship the connecting portion of acooperating interlocking block whose first side surface is opposite tothe first side surface (17) of the block (10); and a channel (26) opento the block top surface (12) extending generally parallel to the outerblock wall and having two opposed channel side walls (28, 30) and achannel bottom wall (32).
 3. A block (10) for use in interlocking withother similar blocks in forming a substantially horizontal channel (52)in a building wall (54), the block comprising: a top surface (12); abottom surface (14); an outer block wall (16) defining a first sidesurface (17) of the block; a head portion (18) extending from the outerblock wall toward an opposed, second side surface (20); two connectingportions (22) each on a respective side of the head portion; twoabutment portions (36) each at a respective end of the outer block walland each defining a respective abutment shoulder (38); a central groove(40) in the head portion at a position thereon opposite to the outerblock wall (16), the groove at opposite ends thereof defining twoinwardly facing shoulders (42) each for engaging and retaining theabutment portion of a respective one of two abutting blocks such thatthe abutment portions (36) are retained end to end within the centralgroove (40); wherein there is defined between the abutment portion andthe connecting portion a receptacle (24) substantially matching in shapethe connecting portion (22) for receiving in interlocking relationshipthe connecting portion of a cooperating interlocking block; and whereinthe block defines a channel (26) open to the block top surface (12)extending substantially parallel to the outer block wall (16) and havingtwo opposed channel side walls (28, 30) and a channel bottom wall (32).4. A block according to claim 1, 2 or 3 wherein the channel bottom wall(32) is spaced from the block bottom surface (14) by a distance that isgreater than the distance between the channel bottom wall and the blocktop surface (12).
 5. A block according to any one of claims 1-4 whereinthe block defines a hole (34) extending therethrough generallyperpendicular to the block bottom surface.
 6. A building wall (54)comprising: a plurality of interlocking blocks (1), at least some of theblocks each comprising: a top surface (12); a bottom surface (14); anouter block wall (16) defining a first side surface (17) of the block; ahead portion (18) extending from the outer block wall toward an opposed,second side surface (20); a connecting portion (22) on the head portion;two abutment portions (36) each at a respective end of the outer blockwall (16); a receptacle (24) substantially matching in shape theconnecting portion; a channel (26) open to the block top surface (12)extending substantially parallel to the outer block wall and having twoopposed channel side walls (28, 30) and a channel bottom wall (32); theblocks being arranged to define a first series (44) of the blocks inwhich the first side surface (17) of each of the first series of blocksis arranged to form a first vertical side surface (46) of the wall, anda second series (48) of the blocks in which the first side surface (17)of each of the second series of blocks is arranged to form a secondvertical side surface (50) of the wall opposite to the first verticalside surface (46); the blocks being interlocked such that: two abutmentportions (36) each of a respective one of two adjacent blocks of thesecond series (48) are positioned end to end; two abutment portions eachof a respective one of two adjacent blocks of the first series arepositioned end to end ; the receptacle (24) of each of the first seriesof blocks receives in interlocking relationship a respective connectingportion (22) of the second series of blocks; the receptacle of each ofthe second series of blocks receives in interlocking relationship arespective connecting portion of the first series of blocks; the channelbottom wall (32) of each of the blocks of the first series is spacedfrom and opposite to the channel bottom wall of a respective one of theblocks of the second series; and the channels (26) of the blocks of thefirst series and of the second series together form a wall channel (52)extending generally horizontally through the building wall (54).
 7. Abuilding wall (54) comprising: a plurality of interlocking blocks (10),at least some of the blocks each comprising: a top surface (12); abottom surface (14); an outer block wall (16) defining a first sidesurface (17) of the block; a head portion (18) extending from the outerblock wall toward an opposed, second side surface (20); two connectingportions (22) each on a respective side of the head portion; twoabutment portions (36) each at a respective end of the outer block wall(16) and each defining a respective abutment shoulder (38) on a face ofthe outer block wall opposite to the first side surface thereof; tworeceptacles (24) each arranged between a respective one of the abutmentportions (36) and a respective one of the connecting portions (22); acentral groove (40) in the head portion at a position thereon oppositeto the outer block wall, the groove at opposite ends thereof definingtwo inwardly facing opposed shoulders (42); and a channel (26) open tothe block top surface (12) extending substantially parallel to the outerblock wall and having two opposed channel side walls (28, 30) and achannel bottom wall (32); the blocks being arranged to define a firstseries (44) of the blocks in which the first side surface (17) of eachof the first series of blocks is arranged to form a first vertical sidesurface (46) of the wall and a second series (48) of the blocks in whichthe first side surface (17) of each of the second series of blocks isarranged to form a second vertical side surface (50) of the wallopposite to the first vertical side surface (46); the blocks beinginterlocked such that: two abutment portions (36) each of a respectiveone of two adjacent blocks of the second series (48) fit into thecentral groove (40) in an opposed one of the blocks of the first series(44) such that the abutment portions are retained end to end within thecentral groove; two abutment portions each of a respective one of twoadjacent blocks of the first series fit into the single central groovein an opposed one of the blocks of the second series such that theabutment portions are retained end to end within the single groove; eachreceptacle (24) of each of the first series of blocks receives ininterlocking relationship a respective one of the connecting portions(22) of the second series of blocks; each receptacle of each of thesecond series of blocks receives in interlocking relationship arespective one of the connecting portions of the first series of blocks;the channel bottom wall (32) of each of the blocks of the first seriesis spaced from and opposite to the channel bottom wall of a respectiveone of the blocks of the second series; and wherein the channels (26) ofthe blocks of the first series and of the second series together form awall channel (52) extending generally horizontally through the buildingwall (54).
 8. A building wall according to claim 6 or 7 furthercomprising a reinforcing member (58) extending through the wall channel(52).
 9. A building wall according to claim 8 further comprising mortarin said wall channel.